Case studies in industry and services
Ayyappan Solaiyappan
Abstract
To enhance the manufacturing process capability of a refractory company, the scope for implementing the Lean Six Sigma (LSS) methodology is analyzed in this work. The DMAIC methodology of Six Sigma is used in this project to determine the Critical to Quality Characteristics (CTQs), defining the possible ...
Read More
To enhance the manufacturing process capability of a refractory company, the scope for implementing the Lean Six Sigma (LSS) methodology is analyzed in this work. The DMAIC methodology of Six Sigma is used in this project to determine the Critical to Quality Characteristics (CTQs), defining the possible causes, identifying the variation in sources, establishing the variable relationships, and implementing the control plans. It was found from the DMAIC approach that the quality of Raw Crude, Water Content, and the frequency of using Temperature Calibration Equipment are the main factors responsible for lowering Productivity in Shaft Kiln. To improve the productivity of Kiln, it was suggested to process the raw crude free of mud, remove the moisture content present in the magnesite stones and take action on changing the frequency of measuring the oil feeding calibration equipment.
Case studies in industry and services
Boby John; Abdulrahiman Areshankar
Abstract
Six Sigma is a structured and systematic approach to performance and quality improvement. Six Sigma is a rigorous methodology consists of five major phases, namely definition, measure, analysis, improvement, and control for problem solving. A lot of case studies have been published and many large organizations ...
Read More
Six Sigma is a structured and systematic approach to performance and quality improvement. Six Sigma is a rigorous methodology consists of five major phases, namely definition, measure, analysis, improvement, and control for problem solving. A lot of case studies have been published and many large organizations have reported financial benefits by the application of Six Sigma methodology. This paper is a case study on reducing the bearing end plate reworks in a machining process through the application of Six Sigma methodology. The study focuses on reducing the rework due to thickness and diameter variation. From the list of identified potential causes, two causes, namely tool type and coolant pH are shortlisted as root causes. The optimum values of tool type and coolant pH, which would simultaneously optimize the diameter and thickness, are identified using the design of experiments and Taguchi's loss function approach. The implementation of optimum settings shows that the capability of the machining process to meet the customer requirements on thickness and diameter has substantially improved and rework has reduced.
